2003 FORD EXPEDITION

6 recalls, 800 complaints - 159 TSBs

EXTERIOR LIGHTING

Defect Description

SABERSPORT IS RECALLING 16,270 COMBINATION CORNER AND BUMPER LAMP ASSEMBLIES OF VARIOUS PART NUMBERS SOLD FOR USE AS AFTERMARKET EQUIPMENT FOR VARIOUS PASSENGER VEHICLES. THESE HEADLAMPS FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES... Read more

Consequence

DECREASED LIGHTING VISIBILITY MAY RESULT IN A VEHICLE CRASH.

Remedy

SABERSPORT WILL NOTIFY OWNERS AND OFFER A FULL REFUND FOR THE NONCOMPLIANT COMBINATION LAMPS. THE SAFETY RECALL BEGAN ON MAY 11, 2009. OWNERS MAY CONTACT SABERSPORT AT 1-909-598-7589.

16,270 vehicles affected

Manufacturer: SABERSPORT

EXTERIOR LIGHTING

Defect Description

CERTAIN TRADESONIC COMBINATION LAMPS SOLD AS REPLACEMENT LAMPS FOR USE ON THE ABOVE LISTED PASSENGER VEHICLES. COMBINATION LAMPS NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM WITH THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED ... Read more

Consequence

LACK OF AMBER SIDE REFLECTORS IN THE LAMPS WILL DECREASE LIGHTING VISIBILITY TO OTHER DRIVERS AND MAY POSSIBLY RESULT IN A VEHICLE CRASH.

Remedy

TRADESONIC WILL NOTIFY OWNERS AND REPLACE THE LAMPS FREE OF CHARGE. THE RECALL IS EXPECTED TO BEGIN DURING JULY 2006. OWNERS MAY CONTACT TRADESONIC AT 626-934-8884.

4,029 vehicles affected

Manufacturer: TRADESONIC

EXTERIOR LIGHTING

Defect Description

CERTAIN PRO-A MOTORS CORNER LAMPS, TURN SIGNALS, AND HEADLIGHTS SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES LISTED ABOVE. SOME COMBINATION LAMPS THAT ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, LAMPS, REFLECTIVE D... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

PRO-A MOTORS WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE LAMPS. THE RECALL BEGAN ON APRIL 3, 2006. OWNERS MAY CONTACT PRO-A MOTORS AT 323-838-2988.

61,944 vehicles affected

Manufacturer: PRO-A MOTORS, INC.

EXTERIOR LIGHTING:HEADLIGHTS

Defect Description

CERTAIN POLI-AUTO COMBINATION HEADLAMP ASSEMBLIES, P/NOS. 11-728, 11-728D, 11-710, 11-419, 11-713, 11-703, 11-704, 11-708P, 11-735, 11-725, 11-726, 11-716 (P&C), 11-721-1, 11-733, 11-729, 11-730, AND 11-732, SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS THA... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH WITHOUT WARNING.

Remedy

POLI-AUTO WILL NOTIFY OWNERS AND OFFER TO REPURCHASE THE HEADLAMPS AT ITS ORIGINAL PURCHASE PRICE. THE RECALL IS EXPECTED TO BEGIN DURING APRIL 2006. OWNERS MAY CONTACT POLI-AUTO AT 305-477-1356.

1,450 vehicles affected

Manufacturer: POLI-AUTO, INC.

EXTERIOR LIGHTING:HEADLIGHTS

Defect Description

CERTAIN ANZO COMBINATION HEADLAMP ASSEMBLIES SOLD AS REPLACEMENT LAMPS FOR USE ON CERTAIN PASSENGER VEHICLES. SOME COMBINATION LAMPS ARE NOT EQUIPPED WITH AMBER SIDE REFLECTORS WHICH FAIL TO CONFORM TO FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 108, "LAMPS, REFLECTIVE DEVICES, AND ASSOCIATED EQUIPME... Read more

Consequence

WITHOUT THE AMBER REFLECTORS, THE VEHICLE WILL BE POORLY ILLUMINATED, POSSIBLY RESULTING IN A VEHICLE CRASH.

Remedy

ANZO WILL NOTIFY OWNERS AND REPLACE THE HEADLAMPS FREE OF CHARGE. THE RECALL BEGAN MAY 9, 2006. OWNERS MAY CONTACT ANZO USA AT 909-468-3688.

292,000 vehicles affected

Manufacturer: ANZO USA, INC.

STRUCTURE

Defect Description

CERTAIN PICKUP TRUCK, VAN, AND MINI VAN CONVERSIONS EQUIPPED WITH SOUTHERN COMFORT BUILT RUNNING BOARDS THAT CONTAIN CERTAIN COURTESY LIGHTS MANUFACTURED BY AMERICAN TECHNOLOGY COMPONENTS, INC. THESE UNITS CONTAIN A COURTESY LIGHT OR LIGHTS THAT MIGHT OVERHEAT WHEN THE WIRE HARNESS IS EXPOSED TO EX... Read more

Consequence

THIS OVERHEATING CONDITION CAN CAUSE THE RUNNING BOARD TO MELT OR CAUSE A FIRE.

Remedy

DEALERS WILL REPLACE THE WIRING HARNESS ON THESE RUNNING BOARDS. OWNER NOTIFICATION BEGAN MARCH 7, 2003. OWNERS WHO TAKE THEIR VEHICLES TO AN AUTHORIZED DEALER ON AN AGREED UPON SERVICE DATE AND DO NOT RECEIVE THE FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT SOUTHERN COMFORT AT 1-800-745-60... Read more

3,674 vehicles affected

Manufacturer: SOUTHERN COMFORT CONVERSIONS

Complaint Statistics

800 total complaints 79 crashes 43 fires 95 injuries 4 deaths

Top Reported Components

Component	Complaints
ELECTRICAL SYSTEM	85
ENGINE AND ENGINE COOLING	70
ENGINE AND ENGINE COOLING:ENGINE	43
ENGINE	43
TIRES	33
AIR BAGS	33
UNKNOWN OR OTHER	21
FUEL/PROPULSION SYSTEM	19
VISIBILITY:REARVIEW MIRRORS/DEVICES:EXTERIOR	19
POWER TRAIN:AUTOMATIC TRANSMISSION	18

Incident date: Mar 8, 2026

the car burns through oil at an absurd rate- no warning and then shakes when coming to a stop, then completely stalls and shuts off at stop lights and stop signs. I was stuck in an intersection with my two kids in the car. the car stinks of gasoline and does not seem right. Kia dealership claimed t... Read more

Incident date: Jul 11, 2024

The contact owns a 2016 Honda Odyssey. The contact stated while driving at undisclosed speeds, the vehicle experienced a loss of automotive power. The contact was able to coast to the side of the road and noticed several unknown warning lights illuminated. The vehicle was taken to the dealer and an ... Read more

Incident date: May 5, 2024

I lost control of vehicle while driving because the electrical steering motor stopped working. I’ve had the electric starter already replaced twice with Honda parts and it’s still not working. There’s something wrong with the steering. I already placed a complaint and I have not heard back f... Read more

Incident date: Dec 7, 2023

If any liquid or debris material enters the console cover area where many controls for the car are located, the “command switch” (as described by the Mazda dealer) underneath is destroyed. Many items are affected as noted above (some of which I could not check off). They have not responded as to... Read more

Incident date: Dec 7, 2023

The contact owns a 2014 Hyundai Elantra. The contact received notification of NHTSA Campaign Number: 23V651000 (Service Brakes, Hydraulic) however, the part to do the recall repair was not yet available. The local dealer was made aware of the issue. The contact stated that the manufacturer had excee... Read more

Incident date: Dec 7, 2023

Incident date: Dec 8, 2023

The contact owns a 2022 Forest River Crossroads Zinger RV trailer hauled by a 2015 Ram 1500. The contact stated that the RV was having water intrusion failures. The contact stated that the RV had water entering from the roof. The RV was not kept under a car port or tarpaulin. The contact stated that... Read more

Incident date: Dec 8, 2023

Was in a head on collision going 40-45 mph. Hit a guard rail head on and airbags did not deploy

Crash 1 injured

Incident date: Dec 8, 2023

I own a 2016 Subaru Crosstrek with only 37,000 miles. There is a problem with my battery being drained after not driving the car for several days. I have had to call for a jump start 3 times, Aug. 8, 2023, Sept. 5, 2023 and Nov. 14, 2023, each time after returning from vacation. I replaced the ba... Read more

Incident date: Dec 26, 2017

The contact owns a 2003 Ford Expedition. The contact stated while driving 45 MPH, the engine was misfiring, and the contact smelled a burning odor inside the vehicle. The check engine warning light was illuminated. The contact was able to drive to his residence. The contact stated that the failure h... Read more

Incident date: Dec 26, 2017

Incident date: Mar 30, 2022

bought truck 3/2/22 from Gold cAuto In troy NY. 3/7/22 went to take kids to school 2.5 inches of water set in my weather guard mats. seats soaked console everything in front cab reversed to pull out spot and water starting pouring on my and my kids from sides in pass sides front and the front wind... Read more

Incident date: Mar 30, 2022

Incident date: Oct 28, 2021

This vehicle has a faulty engine. The aluminum that Ford used to create the top end is too thin to support the pressure of the engine. As a result spark plugs explode from the engine at random with no warning. This has happened 5 times even after replacing all spark plugs, numerous coils and having ... Read more

Incident date: Jan 14, 2022

THIS IS THE 2ND TIME IT HAPPENED TO MY 2003 FORD EXPEDITION. WHILE DRIVING HEARD A LOUD POPPING NOISE, FOLLOWED BY CONTINUOUS POPPING LOUD POPPING NOISE LIKE A BROKEN EXHAUST MUFFLER, SOUNDED LIKE A MOTORCYCLE. AFTER INVESTIGATING, FOUND OUT THAT THE #3 SPARK PLUG POPPED OUT (EJECTED) OF THE HEAD CY... Read more

Incident date: Jan 14, 2022

Incident date: Jun 1, 2014

Faulty fuse panel. This is a known issue. It is ALL over the internet. There has never been a recall. The vehicle will stall while driving. On attempting restart or crank, there is a buzzing noise from the fuse panel. The pcm #203 I believe, corrodes or melts through the board on the panel causing... Read more

Incident date: Jan 15, 2021

THIS SUV STALLED ON THE HIGHWAY WHILE DRIVING IN TRAFFIC. IT WAS CAUSED BY A FAULT IN THE FUEL PUMP OR FUEL PUMP RELAY. PLEASE RECALL THIS VEHICLE.

Incident date: Sep 20, 2016

FUEL PUMP RELAY SHORTED OUT IN MOTION. HIGHWAY AND CITY STREETS. STEERING LOCKS UP ENGINE JUST DIES IN MOTION. SUPER DANGEROUS AND SCARY REPLACED FUSE BOX AND SAME THING HAPPENED AGAIN. NO POWER STEERING ENGINE JUST DIES IN MOTION. SO SCARY ON HIGHWAY 75 MPH.

Fire

Incident date: Sep 20, 2016

Fire

Incident date: Sep 20, 2016

Fire

Incident date: Oct 17, 2020

LOSS OF HEADLIGHTS WHEN USING AUTO CONTROL, SINCE THIS IS AN 03' I BELIEVE HEADLIGHT CONTROL UNIT IS BAD AS THIS SAME UNIT WAS RECALLED ON MY 03' CROWN VICTORIA

Incident date: Jul 7, 2020

FUEL TANK VAPOR RECOVERY UNIT DEVELOPED A CRACK DUE TO MANUFACTURING DEFECTS IN PLASTIC WELD, PERMITTING GASOLINE VAPOR AND GASOLINE FUEL TO ESCAPE FROM THE FUEL TANK IN AN UNCONTROLLED AND UNSAFE WAY. THE PROBLEM MANIFESTED AS A FUEL VAPOR LEAK WHEN THE VEHICLE WAS PARKED ON A 0-DEGREE SURFACE (LE... Read more

Fire

Incident date: Jun 22, 2020

MY FUSE AND RELAY PANEL HAS A DEFECT AND NOW MY TRUCK WON'T START. *TR

Incident date: Jun 22, 2020

MY FUSE AND RELAY PANEL HAS A DEFECT AND NOW MY TRUCK WON'T START. *TR

Incident date: Jun 1, 2020

WAS DRIVING CAR HAD AT LEAST 80 MILES WHEN CAR CUT OFF AT LIGHT IN WOULD NOT COME BACK ON SO I HAD REPLACED FUEL PUMP ONLY TO FIND OUT MY FUSE BOX ISN'T READING MY FUEL RELAYS FROM THE BURNING RELAYS REPLACED. *TR

Incident date: Mar 10, 2020

AS MY FIANCE WAS COMING FROM WORK THE CAR SUDDENLY JUST QUIT ON HIM WHILE DOING 75 MPH. HE GUIDED THE CAR TO THE SIDE OF THE ROAD TO A COMPLETE STOP. HE TRIED TO CRANK THE CAR AGAIN TO ONLY HEARING A BUZZING SOUND. THE FIRST MECHANIC THOUGHT IT WAS THE STARTER SO HE CHANGED IT OUT. THE VEHICLE STILL... Read more

Incident date: May 1, 2019

SUNROOF LEAKS BADLY IT HAS FUSE BOX SHORTING OUT. WHEN IT RAINS MY WINDOWS GO UP DOWN ALONE. ALL LIGHTS SHORTED OUT AND NOTHING WORKING ANY LONGER

Incident date: May 1, 2019

SUNROOF LEAKS BADLY IT HAS FUSE BOX SHORTING OUT. WHEN IT RAINS MY WINDOWS GO UP DOWN ALONE. ALL LIGHTS SHORTED OUT AND NOTHING WORKING ANY LONGER

Incident date: May 1, 2019

SUNROOF LEAKS BADLY IT HAS FUSE BOX SHORTING OUT. WHEN IT RAINS MY WINDOWS GO UP DOWN ALONE. ALL LIGHTS SHORTED OUT AND NOTHING WORKING ANY LONGER

Incident date: Jun 5, 2019

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. THE CONTACT STATED THAT THE FUSE BOX FAILED. WHILE DRIVING 85 MPH, THE VEHICLE STALLED WITHOUT WARNING, THE STEERING WHEEL SEIZED, AND THE FUSE BOX MADE A BUZZING SOUND. THE CONTACT COASTED THE VEHICLE TO THE SIDE OF THE ROAD, REACHED UNDER THE DASHBOARD,... Read more

Incident date: Sep 29, 2019

KEEPS BLOWING THE FUEL PUMP REPLY. WE HAVE HAD TO REPLACE THE REPLY 4 TIMES IN THE LAST FEW DAYS. AFTER REMOVING THE REPLY FROM THE FUSE PANEL AND LOOKING AT THE PORT IT IS BURNING BOTH FUSE AND FUSE PANEL.THIS HAPPEN WHEN WE ARE RUNNING AND WHEN THE FUSE BLOWS IT KILLS THE VEHICLE RIGHT AWAY IN THE... Read more

Incident date: Aug 16, 2019

THIS HAS HAPPENED 3 TIMES, FIRST TIME STOPPED AT A RED LIGHT, WHEN FOOT WAS PUT ONTO GAS TO GO VEHICLE INSTANTLY LOST POWER WITH NO STUTTERING OR STALLING AND HAD TO PUT IN PARK TURN KEY OVER TO GO AGAIN. SECOND TIME, GOING 65 DOWN THE HIGHWAY VEHICLE SUDDENLY ACTED LIKE IT LOST POWER AND SPEED DECR... Read more

Incident date: Aug 16, 2019

Incident date: Apr 1, 2018

I HAVE A HUGE PROBLEM WITH MY 03 FORD EXPEDITION SHUTTING OF RANDOMLY IT IS VERY DANGEROUS ON HIGHWAYS YOU LOSE POWER STEERING AND ALL POWER TO MOTOR ALMOST CAUSED ACCIDENTS MANY TIMES I BELIEVE MANY PEOPLE HAVE THIS PROBLEM AND IT ALL RELATES TO THE FUSE BOX PLEASE MAKE THIS A RECALL SO MANY PEOPLE... Read more

Crash

Incident date: Apr 1, 2018

Crash

Incident date: Jul 8, 2019

THE TRUCK WOULD JUST TURN OFF WHILE DRIVING AT 55 OR 60 MILES AN HOUR , NO STEERINGWAS ON HIGHWAY ,NO BRAKES PUT IN NEURAL TO GET TO SIDE OF ROAD WITH CARS ALL AROUND ME .THIS HAS HAPPENED 3 TIMES, THEN IT WOULD NOT START AT ALL WHEN FULLED UP WITH GAS, HAD TO BE TOWED, THEN WHEN I WAS DOWN TO 1/4 T... Read more

Incident date: Jul 8, 2019

Incident date: Jun 19, 2019

TL* THE CONTACT OWNS A 2003 FORD EXPEDITION. WHEN THE CONTACT STARTED THE VEHICLE, THE ENGINE MADE AN ABNORMAL POPPING SOUND. THE SOUND WAS A DISTRACTION TO THE CONTACT'S DRIVING. THE VEHICLE SHOOK FROM THE BEGINNING OF THE RIDE TO THE END AND THE MAINTENANCE REQUIRED INDICATOR ILLUMINATED. THE DEAL... Read more

Incident date: May 3, 2019

THE VEHICLE WAS STATIONARY, WHEN UNLOCKING THE VEHICLE WITH THE KEYLESS ENTRY, IT MOVED THE SIDEVIEW MIRRORS AND NEVER MOVWS BACK. I PUT THE MIRRORS BACK WHERE THEY BELONG AND EVERY FOLLOWING TIME WHEN I UNLOCK THE VEHICLE WITH THE KEY FOB, IT CONTINUES TO DO THE SAME. I BOUGHT THE VEHICLE THIS WAY.

Incident date: May 3, 2019

Incident date: Feb 1, 2019

FUEL TANK CRACK AND LEAKS

Incident date: Dec 1, 2018

CHECK ENGINE LIGHT CAME ON WHILE DRIVING HOME AND THE ENGINE SHUT DOWN 4 TIMES EACH TIME THE BATTERY WOULD DIE INSTANTLY. WE HAD TO KEEP JUMP STARTING IT TO GET HOME. 2 DAYS LATER THE CHECK ENGINE LIGHT STARTED FLASHING. SCANNED IT CAME BACK P0304 CYLINDER 5 MISFIRE. CHANGED SPARK PLUGS AND COILS. E... Read more

Incident date: Dec 1, 2018

Incident date: Nov 1, 2018

"TAKATA RECALL" I WAS DRIVING DOWN THE INTERSTATE AT 65 MPH WHEN MY TRUCK JUST CUT OFF, HAD TO HAVE IT TOWED IN TO THE SHOP. HAD FUEL PUMP REPLACE, 2 WEEKS LATER SAME PROBLEM.HAD TO HAVE IT TOWED AGAIN FUSE WAS REPLACE. 3 WEEKS LATER I'M NOW HAVING TO HAVE THE FUSE BOX REPLACE. FORD MOTOR COMPANY DO... Read more

Incident date: Nov 1, 2018

Showing 50 of 800 complaints.

Technical Service Bulletins, 2003 FORD EXPEDITION

159 manufacturer communications from 153 unique bulletins. TSBs describe known problems and recommended fixes from the manufacturer.

Most Affected Components

Component	Bulletins
106000 POWER TRAIN:AXLE ASSEMBLY	19
110000 ELECTRICAL SYSTEM	18
061000 ENGINE AND ENGINE COOLING:ENGINE	10
357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER	5
190000 TIRES	5
100000 POWER TRAIN	5
021230 SUSPENSION:FRONT:SPRINGS:AIR SUSPENSION SYSTEM	4
160000 STRUCTURE	4

160000 STRUCTURE

For 2000-2024 Ford and Lincoln vehicles, swapping a module from a vehicle for diagnosis purposes is likely to cause errors and is not recommended. It is also not recommended to order a replacement module using a vehicle identification numbe

100000 POWER TRAIN

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 (non-Raptor) vehicles equipped with 4WD may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (IW

110000 ELECTRICAL SYSTEM

Some 2003-2020 Expedition/Navigator and 2006-2020 F-150 vehicles equipped with TOD transfer cases may exhibit grinding/clicking/ratcheting noise from the front wheel area. This may be due to partial engagement of the integrated wheel ends (

200000 WHEELS

350000 EQUIPMENT

160000 STRUCTURE

This article supersedes TSB 19-2026 to update the vehicle model years affected. Some 2000 and newer Ford/Lincoln/Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint wi

160000 STRUCTURE

Some 2000 and newer Ford, Lincoln and Mercury vehicles equipped with aluminum body panels may exhibit corrosion concerns appearing as bubbled and/or peeling paint with or without accompanying white dust. Panel replacement is recommended. Fo

160000 STRUCTURE

350000 EQUIPMENT

106200 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

106220 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL

FORD: SOME VEHICLES MAY EXHIBIT OIL SEPARATION FROM THE INTERNAL LUBE FOUND IN THE UNITIZED CARTRIDGE SEAL. OIL SEPARATION APPEARS TO BE AND IS OFTEN MISDIAGNOSED, AS AN AXLE LUBE LEAK. *PE

061000 ENGINE AND ENGINE COOLING:ENGINE

SOME 1997-2008 VEHICLES EQUIPPED WITH A 4.6L 2V, 5.4L 2V, OR 6.8L 2V ENGINE--SPARK PLUG THREAD REPAIR PROCEDURE--NOT COVERED UNDER NEW VEHICLE LIMITED WARRANTY. *NJ THIS INCLUDES F-53 MOTORHOME CHASSIS. UPDATED 2/23/10. *PE

030000 SERVICE BRAKES, HYDRAULIC

BRAKE SHUDDER (ROTOR THICKNESS VARIATION) DUE TO THE NEW LOW DUST FRONT BRAKE LINING USED IN PRODUCTION, OR NEW LININGS THAT WERE INSTALLED PER TSB 04-05-02. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

LIMITED SLIP AXLE CHATTER, SHUDDER, BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNING MANEUVERS. *TT

190000 TIRES

LOW TIRE INDICATOR ON - TPMS SYSTEM SENSOR WAKE UP. *TT

060000 ENGINE AND ENGINE COOLING

WDS COP KIT DIAGNOSTIC TIP - COIL ON PLUG (COP) IGNITION SYSTEMS - ENGINE MISFIRE OR ROUGH RUNNING. *TT

221600 SEATS:FRONT ASSEMBLY:POWER ADJUST

DRIVERS FRONT POWER SEAT WILL NOT MOVE FORWARD OR REARWARD. *TT

137000 VISIBILITY:REAR WINDOW WIPER/WASHER

REAR WINDOW WIPER INOPERATIVE. *TT

104000 POWER TRAIN:TRANSFER CASE (4-WHEEL DRIVE)

A TINY CRACK, OR CRACKS, AROUND THE TRANSFER CASE DRAIN PLUG HOLE. *TT

106220 POWER TRAIN:AXLE ASSEMBLY:AXLE SHAFT:SEAL

AXLE SEAL LEAKS. LEAKS FROM REAR HALFSHAFT AXLE SEAL. SERVICE TIPS. *TT

151300 SEAT BELTS:FRONT:RETRACTOR

SAFETY BELT RETRACTION SPEED. *TT

161000 STRUCTURE:FRAME AND MEMBERS

CLUNK/GRIND/THUMP NOISE - FRAME REPAIR PROCEDURE. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE SEAL LEAKS. *EH

010000 STEERING

STEERING WHEEL AT 65 MPH (105 KM/H) OR HIGHER. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE NOISE REPAIR. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

USE OF STAINLESS STEEL EXHAUST STUDS IN SERVICE FOR 5.4L 2V ENGINE. *TT

063130 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:EMISSION CONTROL:GAS RECIRCULATION VALVE (EGR VALVE)

INTERMITTENT ROUGH IDLE - NON-COMMANDED EGR (EXHAUST GAS RECIRCULATION VALVE) FLOW. *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

FALSE PARKING AID WARNINGS. *TT UPDATE. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE HOWL. THIS INCLUDES 1997-05 FORD VEHICLES. *EH

200000 WHEELS

ALUMINUM ALLOY WHEELS PITTING AND OR PEELING CLEANING PROCEDURES. *EH

150000 SEAT BELTS

SAFETY BELT WEB STOP BUTTON SERVICE. *EH

136000 VISIBILITY:WINDSHIELD WIPER/WASHER

WIPER BLADE CHATTER. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE HOWL SERVICE WITH INDIVIDUAL PARTS INSTEAD OF AN AXLE ASSEMBLY. *EH

021230 SUSPENSION:FRONT:SPRINGS:AIR SUSPENSION SYSTEM

FOUR CORNER LOAD LEVELING AIR SUSPENSION MAY EXHIBIT LEVELING CONCERNS, SUCH AS ONE FRONT CORNER DROPPING. INDIVIDUAL AIR SPRINGS AVAILABLE FOR SERVICE. *TT

100000 POWER TRAIN

TINY CRACK OR CRACKS AROUND THE TRANSFER CASE DRAIN PLUG. *EH

022000 SUSPENSION:REAR

REAR AXLE NOISE REPAIR. *SC

190000 TIRES

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

200000 WHEELS

VIBRATION DIAGNOSIS - TIRE/WHEEL RUNOUT. *TT

050000 PARKING BRAKE

PARKING AID SYSTEM INOPERATIVE. *AK

033000 SERVICE BRAKES, HYDRAULIC:POWER ASSIST

UNINTENDED BRAKE ASSIST. *TT

110000 ELECTRICAL SYSTEM

WARNING INDICATORS-PARKING AID-REVERSE SENSING SYSTEM (RSS) AND FORWARD SENSING SYSTEM (FSS)-FALSE ACTIVATION OF WARNING TONE-SERVICE TIPS. *MJ UPDATE. *TT

221700 SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER

CLIMATE CONTROLLED SEAT DIAGNOSIS - SERVICE TIPS. *TT

162000 STRUCTURE:BODY

ALUMINUM CORROSION - SERVICE TIP. *TT

138200 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:REAR WINDOW

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

103100 POWER TRAIN:AUTOMATIC TRANSMISSION:CONTROL MODULE (TCM/PCM/TECM)

GENERAL (PCM) POWER TRAIN CONTROL MODULE PROGRAMMING PROCEDURES. *TT

135000 VISIBILITY:REARVIEW MIRRORS/DEVICES

REVERSE TILT MIRROR SYSTEM DIAGNOSTICS AND REPAIR. *EH

106000 POWER TRAIN:AXLE ASSEMBLY

GRINDING NOISE FROM FRONT AXLE WHEEL HUBS ON ACCELERATION IN 2WD - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 EXPEDITION/NAVIGATOR. *TT

090000 FUEL SYSTEM, OTHER

MULTIPLE VEHICLES - FUEL LEVEL INDICATION CONCERNS - SERVICE TIP. VARIOUS MODELS INCLUDING 2005 SUPER DUTY F-SERIES, EXCURSION, EXPEDITION, EXPLORER, MOUNTAINEER AND AVIATOR. *TT

190000 TIRES

TIRE FEATHERING AT LOW MILEAGE. OASIS. VARIOUS MODELS INCLUDING 2005 EXPEDITION. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

CHATTER, SHUDDER, A BINDING SENSATION, OR VIBRATION DURING LOW SPEED TURNS ON VEHICLES EQUIPPED WITH THE 9.75 INCH OR 8.8 INCH LIMITED SLIP REAR AXLE. *TT

110000 ELECTRICAL SYSTEM

MALFUNCTION INDICATOR LAMP (MIL) ILLUMINATED - SYSTEM LEAN DIAGNOSTIC TROUBLE CODES (DTC'S) - SERVICE TIPS. VARIOUS MODELS INCLUDING 2004 F-SERIES. *TT

110000 ELECTRICAL SYSTEM

VARIOUS ELECTRIC CONCERNS. INTERIOR ILLUMINATION, QUARTER WINDOWS, MOONROOF FUNCTION, ACCESSORY DELAY, COURTESY LAMPS, ELECTRO CHROMATIC MIRROR, CLIMATE CONTROLLED SEATS, ELECTRONIC PARK BRAKE RELEASE, FLASHER RELAY, AUDIO SYSTEM, ELECTRON

110000 ELECTRICAL SYSTEM

REVERSE SENSING SYSTEM DEFAULTING OFF, SETTING DIAGNOSTIC TROUBLE CODES, OR LOSING COMMUNICATION WITH DIAGNOSTIC SCAN TOOL. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE MISFIRE OR RUNNING - COIL ON PLUG (COP) IGNITION SYSTEMS - WDS COP KIT DIAGNOSTIC TIPS. TO INCLUDE VARIOUS 2005 MODELS. * AR THIS ARTICLE 04161 SUPERSEDES TSB 03-14-04.

061000 ENGINE AND ENGINE COOLING:ENGINE

MISFIRE AT IDLE WITH DIAGNOSTIC TROUBLE CODES P0300-P0308, P0316. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

REAR WINDOW DEFROSTER GRID/INTEGRAL ANTENNA DIAGNOSIS AND REPAIR - TERMINAL TAB REPAIR. *TT

138120 VISIBILITY:DEFROSTER/DEFOGGER/HVAC SYSTEM:WINDSHIELD:ELECTRICAL HEATING ELEMENT

INOPERATIVE ELECTRIC REAR WINDOW DEFROSTER (HEATED BACKLITE) GRID LINES, INTEGRAL ANTENNA CONCERNS. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

MULTIPLE VEHICLES USING FEHP REAR AXLE FLUID. FLUID USAGE CHANGE. *TT

020000 SUSPENSION

RIDE HEIGHT ISSUES ON AUTOMOBILES WITH AIR SUSPENSION. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) P0320 (IGNITION ENGINE SPEED INPUT CIRCUIT MALFUNCTION). *TT

282100 BACK OVER PREVENTION:WARNINGS:EXTERNAL/PEDESTRIAN ALERT

REVERSE SENSING SYSTEM WARNING CHIME VOLUME LOW. *TT

110000 ELECTRICAL SYSTEM

CHECK AIR SUSPENSION MESSAGE WITH DIAGNOSTIC TROUBLE CODE (DTC) C1724, C1873, AND/OR C1889. *TT

110000 ELECTRICAL SYSTEM

CHARGING SYSTEM WARNING INDICATOR INTERMITTENTLY ON WITH POSSIBLE DIAGNOSTIC TROUBLE CODE (DTC) P0620. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE AT HIGHWAY SPEEDS (40-60 MPH). *TT

022130 SUSPENSION:REAR:SPRINGS:AIR SUSPENSION SYSTEM

AIR SUSPENSION COMPRESSOR NOISE. *TT

130000 VISIBILITY

POP/THUMP NOISE AT END OF WINDOW MOVEMENT AND/OR DRIVER'S WINDOW BOUNCE BACK AND REVERSE TO MID-POSITION. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

INTERMITTENT LOSS OF COOLING OR AIRFLOW FROM A/C SYSTEM AT HIGHWAY DRIVES. *TT

034420 SERVICE BRAKES, HYDRAULIC:FOUNDATION COMPONENTS:DRUM:SHOES/LININGS

BRAKE DUST - REVISED BRAKE LININGS - VEHICLES BUILT PRIOR TO 12/18/2003. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

REAR AXLE HALFSHAFT SEAL LEAK. *TT

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

TIRE PRESSURE MONITORING SYSTEM (TPMS) LOW TIRE OR TIRE VERY LOW MESSAGE AND/OR THE TPMS LIGHT ON. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE AT HIGHWAY SPEEDS (40-60 MPH). *TT

020000 SUSPENSION

RIDE HEIGHT ISSUES. *TT

151200 SEAT BELTS:FRONT:WEBBING

SAFETY BELT DIFFICULT TO PULL OUT DUE TO WEB STOP BUTTON USED FOR VEHICLE ASSEMBLY. *MJ

162000 STRUCTURE:BODY

INTERIOR CARPET CURLING NEAR THE EMERGENCY BRAKE. *TT

221700 SEATS:FRONT ASSEMBLY:SEAT HEATER/COOLER

CLIMATE CONTROLLED SEAT DIAGNOSIS - SERVICE TIPS. *TT *MJ

330000 INTERIOR LIGHTING

COURTESY RAIL LAMPS DO NOT OPERATE CORRECTLY OR CAUSE A BATTERY DRAW. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

AXLE WHINE BETWEEN 58-62 MPH. *TT

106000 POWER TRAIN:AXLE ASSEMBLY

CLICK/POP/CREAK FROM REAR AXLE. *TT

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) P0320 WITH POSSIBLE DRIVEABILITY CONCERNS AND/OR CHARGING SYSTEM WARNING INDICATOR ON WITH POSSIBLE DTC P0620. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE-ROMEO BUILT 4.6L 2V-TICK NOISE FROM ENGINE-ENGINES BUILT BEFORE 9/17/2003. *MJ

199000 TIRES:PRESSURE MONITORING AND REGULATING SYSTEMS

TIRE PRESSURE MONITORING SYSTEM (TPMS) MODULE CONFIGURATION - SERVICE TIP. *MJ

110000 ELECTRICAL SYSTEM

DIAGNOSTIC TROUBLE CODE (DTC) P0320 WITH DRIVEABILITY SYMPTOMS. *MJ

203000 WHEELS:LUGS/NUTS/BOLTS/STUDS

CORRECT LUG NUT TORQUE SPECIFICATIONS - INCREASE WHEEL NUT AND STUD SIZE - SERVICE TIP. *TT

090000 FUEL SYSTEM, OTHER

FUEL SIGNAL TO INSTRUMENT CLUSTER SERVICE TIP. *TT

063200 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM:MANIFOLD/HEADER/MUFFLER/TAIL PIPE

BROKEN EXHAUST MANIFOLD STUDS. *TT

357100 EQUIPMENT:APPLIANCE:AIR CONDITIONER

LOSS OF CLIMATE CONTROL COOLING DURING EXTENDED DRIVING. *TT

030000 SERVICE BRAKES, HYDRAULIC

ACCUMULATION OF BRAKE DUST ON THE WHEELS UNDER REGULATOR DRIVING CONDITIONS. *TT

353000 EQUIPMENT:ELECTRICAL

PARKING AID SENSOR READINGS DO NOT DISPLAY ON WDS. *TT

220000 SEATS

SEAT CUSHION FOAM DAMAGE/SHREDDING. *TT

121000 EXTERIOR LIGHTING:HEADLIGHTS

EXCESSIVE MOISTURE IN THE HEADLAMP ASSEMBLY. *TT

110000 ELECTRICAL SYSTEM

REMOTE KEYLESS ENTRY (RKE) - SERVICE TIPS. *TT

110000 ELECTRICAL SYSTEM

ADVANCETRAC LIGHTING ON WITH DIAGNOSTIC TROUBLE CODE C1277 (STEERING WHEEL ANGLE 1 AND 2 CIRCUIT FAILURE) OR C1278 (STEERING WHEEL ANGLE 1 AND 2 SIGNAL FAULTED) IN THE IVD MODULE. *TT

063000 ENGINE AND ENGINE COOLING:EXHAUST SYSTEM

MOANING NOISE FROM THE EXHAUST SYSTEM, OR VIBRATION IN THE REAR PASSENGER FLOOR PAN, WHEN DRIVING 45-55 MPH AND 1200-1400 RPM ALL WITHOUT FLEX COUPLING IN THE EXHAUST. *TT

110000 ELECTRICAL SYSTEM

VEHICLES EQUIPPED WITH ADVANCETRAC STABILITY ASSIST/INTERACTIVE VEHICLE DYNAMICS - IVD) MAY EXHIBIT A DIAGNOSTIC TROUBLE CODE C1998. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

SOME VEHICLES, EQUIPPED WITH THE 4.6L 2V ENGINE, WITH AN ENGINE BUILD DATE PRIOR TO 8/29/03 MAY EXHIBIT AN ENGINE TICK NOISE THAT IS PRESENT AT ALL TEMPERATURES DURING IDLE. 2004 MODELS INCLUDED. *TT

162000 STRUCTURE:BODY

NOISE FROM DOOR CLADDING AT HIGHWAY SPEEDS. *TT

061000 ENGINE AND ENGINE COOLING:ENGINE

ENGINE MISFIRE OR ROUGH RUNNING CONDITION WITH COIL ON PLUG (COP) IGNITION SYSTEMS MAY BE MORE ACCURATELY DIAGNOSED USING THE OPTIONAL WORLDWIDE DIAGNOSTIC SYSTEM (WDS) COIL ON PLUG (COP) KIT. 2003 SUPER DUTY F SERIES INCLUDED. *TT

103600 POWER TRAIN:AUTOMATIC TRANSMISSION:COOLING UNIT AND LINES

NEW TRANSMISSION COOLER FLUSHER - SERVICE TIPS. 2003 ESCORT AND SUPER DUTY F SERIES INCLUDED. *TT

021230 SUSPENSION:FRONT:SPRINGS:AIR SUSPENSION SYSTEM

THIS ARTICLE ADDRESSES THE PROPER PROCEDURE TO CLEAR DIAGNOSTIC TROUBLE CODES C1990 OR C1991 FROM THE VEHICLE DYNAMICS MODULE/4-WHEEL AIR SUSPENSION MODULE. *TT

Showing 100 of 159 bulletins.

NHTSA Safety Investigations, FORD EXPEDITION

Investigations opened by NHTSA into potential safety defects. These are separate from recalls and may or may not result in a recall.

AQ, Open , Model Year: 2021

NU Car rental of vehicles with open recalls

NHTSA is opening this Audit Query (AQ) to investigate NU Car Rentals (NU Car) for compliance with the requirements of the National Traffic and Motor Vehicle Safety Act.The Safety Act requires that a rental company shall not rent a vehicle subject to a safety recall unless the recall remedy has been ... Read more

RQ, Closed , Model Year: 2018

Seat Belt Retractor Pretensioner Inadvertent Deployment

On November 22, 2023, the Oﬃce of Defects Investigation (ODI) opened Preliminary Evaluation (PE) PE23021 to investigate complaints of front seat belt retractor pretensioner inadvertent deployment in model year (MY) 2019 Ford Expedition vehicles manufactured by Ford Motor Company. Some complaints a... lleged hearing a loud, explosion-like sound immediately followed by the seat belt tightening around the occupant’s torso area. The complaints did not state that a crash occurred that may have resulted in the deployment of the pretensioner system, suggesting that this deployment was inadvertent or otherwise unwarranted. On February 9, 2024, Ford issued safety recall 24V-099, recalling certain MY 2018-2020 Ford Expedition and Lincoln Navigator vehicles equipped with driver and front passenger seat belt retractor pretensioners built between October 1, 2018, and June 30, 2019. Ford described the defect as a seat belt retractor pretensioner assembly that may develop corroded squib pins, resulting in high resistance or an open circuit, which could result in an inadvertent deployment of a pretensioner and an increased risk of injury due to the loss of the pretensioner’s protection and a seat belt that remains in the locked position. This recall includes 77,574 vehicles. On November 15, 2024, ODI opened this Recall Query (RQ24015) after receiving 3 complaints involving vehicles not included in recall 23V-099 but that alleged a similar failure. As a result of this investigation, Ford issued safety recall 25V-197 on March 28, 2025, to expand the scope of 24V-099 to include MY 2018-2020 Ford Expedition and Lincoln Navigator vehicles equipped with driver and front passenger seat belt retractor pretensioners built between October 1, 2018, and July 31, 2020. This recall includes 105,322 vehicles, some of which are also included in 24V-099. Additionally, on May 23, 2025, Ford issued 25V-197 Amendment #1, which further expands the recall population’s scope for vehicles with build dates of September 2018. This amendment added 7,627 additional vehicles to the 25V-197 population. In response to ODI’s inquiries in RQ24015, Ford indicated that it cannot conclusively determine the root cause of the relevant failure. Ford was able to determine that certain pretensioners may develop corroded squib pins potentially resulting in inadvertent deployment, but it was unable to specify the cause of corrosion. Without a speciﬁc root cause, Ford assessed ﬁeld performance of pretensioners to determine the scope of the recalls. ODI is aware of three vehicles that experienced pretensioner inadvertent deployment that are not included in either 25V-197 or 24V-099. Two of these vehicles are MY 2018 Lincoln Navigator vehicles built prior to October 1, 2018, and both experienced failures after more than six years of use/exposure while the recalled vehicles experienced higher rate of failures with less exposure. The remaining incident involves a MY 2021 Ford Expedition that was built after July 31, 2020. ODI is not aware of any other relevant failures in vehicles built after July 31, 2020. As such, ODI has not currently identified a safety defect trend for this issue in vehicles outside of the recalled populations. ODI will continue to monitor allegations of pretensioner inadvertent deployment in subject vehicles that are not included in 25V-197. In view of the safety recall action being taken by Ford, ODI is closing this Recall Query (RQ24015). The agency reserves the right to take additional action if warranted by future circumstances. To review the reports cited in the Closing Resume ODI Report Identiﬁcation Number document, go to NHTSA.gov.Read more

PE, Closed , Model Year: 2019

Seat Belt Pretensioner Inadvertent Deployment

On November 22, 2023, the Office of Defects Investigation (ODI) opened PE23-021 to investigate instances of seat belt pretensioner inadvertent deployment in model year (MY) 2019 Ford Expedition vehicles manufactured by Ford Motor Company. Some complaints allege hearing a loud, explosion-like sound i... Read more

RQ, Closed , Model Year: 2011

Unexpected Transmission Downshift

The Office of Defects Investigation (ODI) opened an investigation based on consumer allegations of transmissions unexpectedly downshifting to a lower gear without input from the driver on model year (MY) 2011-2013 Ford F-150, Expedition and Navigator vehicles. ODI has received 455 unique reports rel... ated to the alleged problem that were not covered under a previous recall for this issue (16V-248).Expedition and Navigator complaint rates are lower than F-150 complaints. Of those 455 reports, 34.7% claimed that the rear wheels locked up when the transmission downshifted. There were 4 accident claims with no injuries. There are many instances where drivers report leaving their lane or the road because of this issue.In response to ODI's Information Request (IR) letter, Ford Motor Company (Ford) responded with 783 unique reports related to the alleged problem. There were 6 accident claims with 3 injuries. Ford also submitted 1206 warranty claims related to transmission downshifting failures. The failure can occur at any time, but typically at higher speed, and include symptoms such as sudden transmission downshifting, loss of speedometer, erratic shifting of transmission, and transmission stuck in one gear. The failures typically occur without warning and may result in the rear wheels momentarily locking up. The driver often had to fully stop the vehicle and restart it to get the vehicle to shift properly.On February 2nd, 2019 Ford notified ODI that it would conduct a safety recall (19V-075) to remedy transmission downshifting failures on all 2011-2013 F-150 vehicles. Ford will also offer extended warranties to 2011-2013 Expedition and Navigator vehicles with the same issue. Per Ford, some vehicles may experience an intermittent loss of Transmission Output Speed Sensor (OSS) signal to the Powertrain Control Module (PCM), potentially resulting in a temporary unintended downshift into first gear. Ford will reprogram the PCM with software that will prevent an unintended downshift into first gear and illuminate the Malfunction Indicator Light in the event of an intermittent OSS signal loss.The recall action initiated by the manufacturer appears to address the safety risks of concern to ODI.Accordingly, the investigation is closed.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers found in the attached list.Read more

PE, Closed , Model Year: 2004

STEEL WHEEL FRACTURE

FORD SPECIAL SERVICE VEHICLE (SSV) EXPEDITIONS USE A STEEL FULL FACE WHEEL DESIGN SIMILAR TO THAT INVESTIGATED IN PE03009, RQ04007, EA04034 (CROWN VICTORIA POLICE INTERCEPTOR) AND PE03026 (GM PICKUPS AND SUVS).A TOTAL OF 8,251 SSVS (2.2% OF TOTAL PRODUCTION) WERE PRODUCED WITHIN MODEL YEARS 2004-200... 6 AND SOLD PRIMARILY FOR USE BY STATE, FEDERAL, AND MUNICIPAL LAW ENFORCEMENT (LE) AGENCIES.FORD STIPULATES THAT THE SUBJECT VEHICLES ARE NOT SUITABLE FOR HIGH SPEED OR PURSUIT OPERATIONS AND ALSO IDENTIFIED A 2004 NATIONAL INSTITUTE FOR JUSTICE VEHICLE EVALUATION REPORT WHICH ALSO ACKNOWLEDGES THIS LIMITATION. THE FULL FACE WHEEL IS FABRICATED FROM TWO PIECES: A STAMPED OUTER WHEEL DISC AND A FORMED RIM.THE TWO PIECES, WHICH TOGETHER COMPRISE THE OUTER BEAD SEAT, ARE JOINED TOGETHER WITH A CIRCUMFERENTIAL WELD.A CYCLIC BENDING MOMENT OCCURS IN THE OUTER BEAD SEAT AREA AS THE WHEEL ROTATES, RESULTING IN FATIGUE STRESSES IN THE WELD'S HEAT AFFECTED ZONE THAT CAN LEAD TO FRACTURING (CRACKING) OF THE RIM MATERIAL.BECAUSE THE FAILURE OCCURS UNDER THE OUTBOARD TIRE BEAD, AIR LEAKAGE MAY NOT READILY OCCUR WHEN THE RIM CRACKS, DEPENDENT ON HOW WELL THE BEAD SEALS ON THE RIM.IF MULTIPLE CRACKS GROW UNDETECTED AND SUDDENLY JOIN INTO A SINGLE LARGE CRACK, THE WHEEL'S STRUCTURE CAN BECOME COMPROMISED LEADING TO RAPID AIR LOSS.A RAPID AIR LOSS, ESPECIALLY AT HIGHER SPEED, MAY LEAD TO A CRASH. FORD RESPONDED TO ODI'S JANUARY 5, 2009 INFORMATION REQUEST (IR) ON FEBRUARY 24.FORD'S RESPONSE ACKNOWLEDGES A NUMBER OF WHEEL FRACTURES ON THE SSVS.HOWEVER, BASED ON ITS ASSESSMENT OF THE PERTINENT FACTORS, IT CONCLUDES THAT THE CONDITION DOES NOT REPRESENT AN UNREASONABLE RISK TO SAFETY.THE LACK OF REPORTS OF RAPID AIR LOSS, NO ALLEGED CRASHES, AND THEIR ASSESSMENT THAT A CRACKED WHEEL CAN BE DETECTED THROUGH SLOW, REPEATED AIR LOSS OR VIBRATION, WERE THE BASES FOR FORD'S CONCLUSION.FORD DISCUSSES THE RESULTS OF A STUDY IT PERFORMED ON WHEELS RETURNED FROM LE FIELD USE, DESIGN REVISIONS IT MADE TO THE SUBJECT WHEEL, AND THE OUTCOME OF DURABILITY TESTING IT CONDUCTED ON THE OLD AND NEW WHEEL DESIGNS. THE COUNTS SHOWN ABOVE INCLUDE A DUPLICATE ODI AND FORD REPORT; THE FORD COUNTS ARE UNIQUE VEHICLES ALLEGING WHEEL FRACTURE(S).SOME WARRANTY CLAIMS INVOLVED MORE THAN ONE WHEEL REPLACEMENT.ALTHOUGH THE SUBJECT VEHICLES HAVE BEEN IN SERVICE FOR A LONGER PERIOD OF TIME THAN VEHICLES INVESTIGATED IN THE PREVIOUS INVESTIGATIONS OF TWO-PIECE WHEEL FRACTURE, ODI DID NOT IDENTIFY ANY ALLEGATIONS OF CRASHES, RAPID AIR LOSS EVENTS DUE TO WHEEL FRACTURES OR ALLEGATIONS OF EFFECTS ON VEHICLE CONTROL OR STABILITY, AS WERE THE CASES IN PAST INVESTIGATIONS WHERE SAFETY RECALLS WERE CONDUCTED TO REPLACE AFFECTED WHEELS.THE AGENCY AGREES THAT THE SSV IS NOT SUITABLE FOR PURSUIT OR HIGH SPEED USAGE, REDUCING THE POTENTIAL FOR CRASHES OR LOSS OF CONTROL INCIDENTS TO BE CAUSED BY THE ALLEGED DEFECT. FORD IMPLEMENTED A 'SHOT PEENING' PROCESS IN JUNE 2006 WHICH REDUCED THE WHEEL'S SURFACE STRESS AND SIGNIFICANTLY IMPROVED ITS DURABILITY, AND ODI IS UNAWARE OF ANY FAILURES OF SHOT PEENED WHEELS (SERVICE PART NUMBER 7L1Z-1015-B).FORD'S TESTING SHOWED A SLIGHTLY REDUCED DURABILITY FOR THE NON-SHOT PEENED WHEELS WHEN 'LT' INSTEAD OF FORD APPROVED 'P' METRIC TYPE TIRES ARE USED. A SAFETY-RELATED DEFECT HAS NOT BEEN IDENTIFIED AT THIS TIME AND FURTHER USE OF AGENCY RESOURCES DOES NOT APPEAR TO BE WARRANTED.ACCORDINGLY, THIS INVESTIGATION IS CLOSED.THE CLOSING OF THIS INVESTIGATION DOES NOT CONSTITUTE A FINDING BY NHTSA THAT A SAFETY-RELATED DEFECT DOES NOT EXIST.THE AGENCY WILL TAKE FURTHER ACTION IF WARRANTED BY FURTHER CRead more

EA, Closed , Model Year: 1999

WINDSHIELD LEAK CAUSES ELECTRIC FAILURES

CONSUMERS ALLEGED THAT WHEN IT RAINED OR SNOWED, WATER LEAKED INTO THE VEHICLE AROUND THE WINDSHIELD.MOISTURE FLOWING THROUGH THE SEAL THAT SURROUNDS THE FRONT WINDSHIELD FOLLOWS A PATH THROUGH THE SEAL INTO THE GENERIC ELECTRONIC MODULE (GEM) AND FUSE BOX, AND MAY CAUSE THE ELECTRICAL COMPONENTS IN... Read more

PE, Closed , Model Year: 1999

ELECTRICAL SYSTEM FAILURE

ODI HAS RECEIVED 39 REPORTS ALLEGING THAT WATER LEAKS AROUND THE WINDSHIELD CAUSING ELECTRICAL FAILURES, INCLUDING BUT NOT LIMITED TO THE WINDSHIELD WIPERS AND THE HEADLAMPS.FORD REPORTS THAT WATER ENTERING THE VEHICLE CAN WET THE POWER DISTRIBUTION BOX (PDB) AND THE GENERIC ELECTRONIC MODULE (GEM).... Read more

PE, Closed , Model Year: 2000

SPEED CONTROL DEACTIVATION SWITCH FIRE

IN ITS LETTER DATED JANUARY 27, 2005 TO ODI, FORD INDICATED THAT IT WOULD CONDUCT A SAFETY RECALL (NHTSA RECALL # 05V-017) TO REMEDY AN OVERHEATING SPEED CONTROL DEACTIVATION SWITCH IN APPROXIMATELY 738,490 SUBJECT VEHICLES.THE VEHICLES AFFECTED BY THE RECALL ARE CERTAIN 2000 MODEL YEAR (MY) FORD F1... Read more

EA, Closed , Model Year: 1997

STEERING SHAFT SEPARATION

SEE ATTACHED SUMMARY FOR TECHNICAL DETAILS

PE, Closed , Model Year: 1997

FRONT STABILIZER LINK

SQ, Closed , Model Year: 2000

WHEEL STUD AND NUT

IN DECEMBER 1999, FORD ISSUED TECHNICAL SERVICE BULLETIN 99-26-3, ENTITLED INCREASED WHEEL NUT AND STUD SIZE-SERVICE TIP,FOR 2000 MODEL YEAR EXPEDITION, NAVIGATOR, AND CERTAIN F-150 VEHICLES, BUILT ON OR AFTER NOVEMBER 27, 1999.THESE VEHICLES HAVE INCREASED WHEEL STUD AND NUT DIAMETERS FROM 12MM TO ... Read more

PE, Closed , Model Year: 1997

FACTORY INSTALLED TOWING HITCH SEPARATIO

THIS INVESTIGATION WAS OPENED ON SEPTEMBER 27, 1999 BASED ON FIVE CONSUMER REPORTS ALLEGING THAT SOME OF THE EIGHT HITCH MOUNTING BOLTS EITHER BECAME LOOSE OR CAME COMPLETELY OUT OF ITS RETAINING PLATE.ONE OF THE COMPLAINTS INDICATED THAT WHILE TOWIG A TRAILER THE HITCH ACTUALLY SEPARATED FROM THE F... Read more

PE, Closed , Model Year: 1996

TIE ROD END FAILURES

There is no summary currently available

PE, Closed , Model Year: 1997

INDEPENDENT FRONT SUSPENSION TORSION BAR

THREE CONSUMERS HAVE REPORTED FAILURE OF ONE OF THE TWO FRONT SUSPENSION TORSION BARS IN THE SUBJECT VEHICLES.IN ONE CASE THE FAILURE OCCURRED WHILE THE VEHICLE WAS IN OPERATION, AND THE VEHICLES WERE PARKED WHEN THE OTHER TWO FAILURES OCCURRED.NO CRASHES HAVE BEEN REPORTED.TORSION BAR FAILURES ARE ... Read more

FORD EXPEDITION - All Years Overview

Complete safety history for the FORD EXPEDITION across all model years (1997, 2027).

180 Total Recalls

11,797 Total Complaints

14 Investigations

764 Reported Crashes

831 Reported Fires

59 Reported Deaths

FORD EXPEDITION - Year by Year

Compare recalls and complaints across model years. Click any year to see full details.

Year	Recalls	Complaints
2027	1	0	View
2026	1	13	View
2025	5	52	View
2024	7	108	View
2023	8	89	View
2022	12	156	View
2021	12	276	View
2020	18	490	View
2019	11	590	View
2018	14	455	View
2017	4	474	View
2016	3	275	View
2015	3	229	View
2014	0	96	View
2013	0	114	View
2012	3	163	View
2011	0	91	View
2010	0	74	View
2009	1	42	View
2008	4	179	View
2007	2	267	View
2006	6	395	View
2005	5	452	View
2004	4	381	View
2003 (current)	6	800
2002	4	415	View
2001	10	739	View
2000	11	1,136	View
1999	9	1,137	View
1998	7	1,022	View
1997	9	1,065	View
1996	0	3	View
1995	0	1	View
1994	0	4	View
1993	0	1	View
1991	0	1	View

Other FORD Models

Model	Recalls	Complaints
MUSTANG	1,104	11,600	View
RANGER	928	10,371	View
F-350 SD	776	2,363	View
F-150	692	46,142	View
F-450 SD	692	624	View
F-250 SD	638	3,635	View
EXPLORER	624	42,549	View
F-550 SD	578	603	View

Vehicle Safety

Consumer Safety

Infrastructure

Public Health

2003 FORD EXPEDITION

Complaint Statistics

Top Reported Components

Technical Service Bulletins, 2003 FORD EXPEDITION

Most Affected Components

NHTSA Safety Investigations, FORD EXPEDITION

FORD EXPEDITION - All Years Overview

FORD EXPEDITION - Year by Year

Other FORD Models